Installation Manual - ACSIGAS 5000/MDE-4676 PAM... · MDE-4676 PAM™ 5000 Installation Manual ·...

MDE-4676

PAM™ 5000

Installation Manual

Computer Programs and DocumentationAll Gilbarco Inc. and/or Veeder Root Company computer programs (including software on diskettes and within memory chips) and documentation are copyrighted by, and shall remain the property of, Gilbarco Inc. and/or Veeder Root Company. Such computer programs and documents may also contain trade secret information. The duplication, disclosure, modification, or unauthorized use of computer programs or documentation is strictly prohibited, unless otherwise licensed by Gilbarco Inc. and/or Veeder Root Company.

Federal Communications Commission (FCC) WarningThis equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate this equipment.

Approvals

PatentsGilbarco Inc. products are manufactured or sold under one or more of the following US patents:

Dispensers

Point of Sale/Back Office Equipment

Trademarks

4,566,504 4,556,927 4,570,686 4,687,033 4,728,788 4,748,846 4,799,940 4,805,453 4,876,653 4,890,210 4,913,813 4,930,655 4,934,565 4,938,0544,938,251 4,939,730 4,967,366 4,986,445 5,040,577 5,098,179 5,134,548 5,156,199 5,269,353 5,228,084 5,325,706 5,345,979 5,355,915 5,363,9885,384,850 5,407,115 5,417,256 5,448,638 5,450,883 5,464,466 5,501,246 5,535,130 5,542,458 5,543,849 5,546,981 5,557,084 5,571,310 5,602,7455,626,649 5,630,528 5,708,580 5,719,779 5,719,781 5,720,325 5,724,067 5,734,851 5,755,854 5,782,275 5,794,667 5,798,931 5,803,136 5,843,2125,857,500 5,868,179 5,871,651 5,890,520 5,954,080 5,956,259 5,969,691 5,971,042 5,979,705 5,980,090 6,026,866 6,052,629 6,073,840 6,078,8886,078,896 6,082,415 6,085,775 6,087,954 6,089,284 6,092,410 6,098,879 6,102,085 6,109,477 6,112,134 6,113,039 6,116,505 6,119,110 6,123,1186,149,033 6,167,923 6,176,421 6,184,846 6,185,307 6,185,893 6,196,065 6,227,227 6,244,310 6,250,151 6,253,779 6,263,319 6,275,746 6,296,1486,302,165 6,313,737 6,325,112 6,326,934 6,336,479 6,338,369 6,347,649 6,352,176 6,357,493 6,360,137 6,363,299 6,364,206 6,380,853 6,381,5146,386,246 6,418,983 6,421,616 6,422,464 6,431,226 6,438,452 6,460,579 6,463,389 6,466,842 6,470,233 6,493,440 6,499,516 6,505,134 6,522,9476,523,744 6,529,800 6,532,999 6,535,726 6,546,882 6,571,151 6,571,201 6,573,884 6,574,603 6,578,145 6,618,362 6,644,360 6,681,814 6,685,0896,690,275 6,697,705 6,704,774 6,708,797 6,710,701 6,712,101 6,721,669 6,736,313 6,741,909 6,745,104 6,761,190 6,763,974 6,766,949 RE35,238D262,971 D265,092 D306,719 D309,144 D316,471 D413,124 D413,311 D413,336 D413,337 D413,610 D413,901 D413,902 D414,192 D414,501D414,778 D414,779 D414,780 D414,781 D414,782 D415,166 D415,167 D415,168 D415,169 D415,170 D415,171 D415,172 D415,501 D415,777D416,915 D416,916 D417,226 D418,523 D420,684 D421,612 D422,285 D422,604 D426,555 D428,424 D428,897 D429,739 D429,740 D431,039D431,252 D431,573 D432,140 D432,141 D432,548 D432,552 D433,031 D433,032 D433,033 D433,034 D433,035 D433,036 D433,037 D433,420D433,421 D433,422 D433,423 D433,424 D433,685 D433,686 D433,687 D433,688 D434,424 D434,780 D435,051 D440,579 D443,624 D456,820D457,084

4,967,366 5,228,084 5,448,638 5,798,931 5,980,090 5,708,580 5,719,779 5,719,781 5,724,067 5,734,851 6,073,840 6,078,888 6,116,505 6,185,3076,263,319 6,275,746 6,326,934 6,360,137 6,363,299 6,364,206

Gilbarco is an ISO 9001:2000 registered company.Underwriters Laboratories (UL): U L File# Products listed with U L

MH1941 All Gilbarco pumps and dispensers that bear the UL listing mark.

MH8467 Transac System 1000 and PAM 1000E105106 Dell DHM MinitowerE165027 G-SITE and Passport Systems

National Conference of Weights and Measures (NCWM) - Certificate of Conformance (CoC):Gilbarco pumps and dispensers are evaluated by NCWM under the National Type Evaluation Program (NTEP). NCWM has issued the following CoC:CoC# Product Model # CoC# Product Model # CoC# Product Model #02-019 Encore Nxx 02-026 H111B Series AC, RAC 02-034 External Mount CRIND CECXXXXXXX02-020 Eclipse Exx

02-027

MPD-1 Series AN, RAN 02-035 Dimension Dxx

02-021T-12C Console PA0188, RA0188 Fixed Blender AF, RAF, AG,

RAG 02-036 Legacy Jxxx

T-12C Console PA0203, RA0203 Dispenser - Low Profile AR, RAR

02-037

G-SITE Printer (Epson) PA030702-022 T-12G Console PA0180, RA0180

02-028Indoor Card Q11640 G-SITE Distribution Box PA0306

02-023T-15 Console PA0189 Outdoor Card Q11891 G-SITE Keyboard PA0304T-15 Controller C2 PA0211 02-029 CRIND — G-SITE Mini Tower PA0301T-15 Controller PA0190

02-030

TS-1000 Console PA0240 G-SITE Monitor PA0303

02-024

ProBlender AU, RAU TS-1000 Controller PA0241 G-SITE Printer (Citizen) PA0308Precision Blender AE, RAE Distribution Box PA0242 02-038 C+ Meter T19976Dispenser - Standard AK, RAK Micro-T Console PA0250 02-039 Passport PA0324Dispenser - Low Profile AL, RAL Meter - EC Series PA024EC10 02-040 Ecometer T20453Fixed Blender AP, RAF VaporVac Kits CV

02-025Meter - C Series PA024NC10 02-031 The Advantage Series Bxx, RBxxMeter - C Series PA024TC10 02-032 Trimline Series AA, RAASalesmaker ProBlender AB, RAB 02-033 Meter - C Series PA024XC10

99-165 Salesmaker Series 2/2H/4/4A AM MPD-A3 Series AD, RAD

New York City Fire Department (NYFD):NYFD C of A # Product

4805 The Advantage Series and Legacy Series

4986 Encore and Eclipse

California Air Resources Board (CARB):Executive Order # ProductG-70-52-AM Balance Vapor RecoveryG-70-150-AE VaporVac

Registered trademarks Dimension® Series The Advantage® Series Encore®

Gilbarco® Transac® Eclipse®

InfoScreen® Trimline® TRIND®

Legacy® VaporVac® Passport®

Making Things Better® G-SITE® CRIND®

MPD® Transac® System 1000 Performer®

e-CRIND®

Additional US and foreign trademarks pending.

Other brand or product names shown may be trademarks or registered trademarks of their respective holders.

Non-registered trademarks C-PAM™ G-SITE® Lite™ Surge Management System™

CIM™ Highline™ Tank Monitor™

ECR™ MultiLine™ TCR™

EMC™ Optimum™ Series Ultra-Hi™

G-CAT™ PAM™ 1000 ValueLine™

Gilbert™ PAM™

G-Poll™ Interface SMART Connect™

SmartPad™

This document is subject to change without notice. For information regarding Gilbarco Inc. Literature, call (336) 547-5661E-mail: [email protected] Internet: http://www.gilbarco.com© 2008 Gilbarco Inc. All Rights Reserved

mailto: [email protected]

http://www.gilbarco.com

mailto: [email protected]

MDE-4676 PAM™ 5000 Installation Manual · February 2008 Page i

Table of Contents

1 – Introduction 1Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PAM 5000 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4HIMs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Unpacking Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Returning Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Preliminary Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7POS Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8System Regulatory Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2 – Important Safety Information 9

3 – Installation 13PAM 5000 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Additional Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4 – Replacing the Fuse 17Changing a Blown Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

5 – Installation Drawing - HIMs 19

6 – PAM 5000 Configuration 21

Index Index-1

Page ii MDE-4676 PAM™ 5000 Installation Manual · February 2008

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Purpose Introduction

1 – Introduction

PurposeThis manual provides instructions to install the PA03820000 Pump Access Module (PAM™) 5000 System Controller with a nominal voltage of 120 VAC. To configure the PAM 5000 system, refer to MDE-4677 PAM 5000 Service Manual.

This manual is intended for general contractors and Authorized Service Contractors (ASCs) who install Gilbarco® systems. A trained Gilbarco ASC must be present before the units are powered, to install optional kits and to start up the PAM 5000 system.

Do not install the PAM 5000 unless you have been properly trained to do so. Do not install the controller in hazardous locations.

IMPORTANT INFORMATION

Required ToolsThe following tools are required for the installation of the PAM 5000 system:

• Large slotted screwdriver• Small [max 2.5 mm (0.1 inch)] slotted screwdriver• Drill and fasteners to secure the controller to the wall• Cutters

Related DocumentsDocument Number Title GOLD LibraryMDE-2149 Warranty Return Materials Authorization Encore® and Eclipse®

MDE-2713 Universal Distribution Box - Installation Manual POS Peripheral Devices

MDE-2714 Universal Distribution PA0261XXXXXXX Service Manual POS Peripheral Devices

MDE-3620 POS Site Preparation Manual G-SITE® Site Preparation

MDE-4677 PAM 5000 Service Manual Transac® Products

PT-1869 Recommended Spare Parts for Domestic Products Parts Manual Parts Manual

PT-1877 Retail Automation Products Illustrated Parts Manual Parts Manual Parts Manual

MDE-4676 PAM™ 5000 Installation Manual · February 2008 Page 1

Introduction Abbreviations and Acronyms

Abbreviations and AcronymsTerm DescriptionAC Alternating Current

ASC Authorized Service Contractor

CPB Central Processor Board

CRIND® Card Reader in Dispenser

DMB DOMS Multiplex Bus

DSB DOMS Serial Bus

EIA Electronics Industries Association

HIM Hardware Interface Modules

LAN Local Area Network

LED Light Emitting Diode

PAM Pump Access Module

POS Point of Sale

RFI Radio Frequency Interference

STP Submerged Turbine Pump

WAN Wide Area Network

Page 2 MDE-4676 PAM™ 5000 Installation Manual · February 2008

General Information Introduction

General InformationThe PAM 5000 system is a microprocessor-based access module that interfaces to fuel dispensers and the Point of Sale (POS) system.

Optionally, the PAM 5000 system can be equipped with a Card Reader in Dispenser (CRIND) kit, used as an interface between POS and payment terminals.

Figure 1-1: Overview of the PAM 5000 System

WAN Network

Service PC Local Diagnostic

RS-232

Gilbarco

Router

LAN

POS

Optional CRIND Pump

PAM 5000 Pump

CRIND

Service Company Remote Diagnostic


Introduction General Information

PAM 5000 OverviewThe PAM 5000 Central Processor Board (CPB), POS and Pump Hardware Interface Modules (HIMs) are placed inside a metal cabinet. The front portion of the cabinet can be opened as a door using a screwdriver. The AC filter and AC transformer are placed in the bottom portion of the cabinet.

The PAM 5000 basic system provides a pump interface for up to 16 fueling positions and with additional optional interface modules, the system can control up to 36 fueling positions.

Optionally, a special CRIND kit can be added into the system, which interfaces between the POS system and payment terminals.

Figure 1-2: PAM 5000 with Cabinet Lid Open

AC Transformer

Central Processor Board

Ethernet Port (For Diagnostic, Service, and Software Download)

1.4” DIN Rail

Wire Relief Bar

AC Filter

Pump Interface Modules

POS Interface Module


General Information Introduction

The AC cord is a 3 wire (P, N and PE) cord. The cabinet is connected to the earth wire in the AC filter.

Note: The PAM 5000 is a Class 1 equipment.

HIMsThe PAM 5000 system is shipped with HIMs to interface with the POS and pumps. The pump HIM has eight connections, to interface with up to eight pumps (maximum of 16 fueling positions per board). If more pumps need to be controlled, additional HIMs must be ordered and installed. A special CRIND kit must be ordered and installed if an interface between the POS system and payment terminals is required.

The HIMs are printed circuit boards mounted in DIN-rail housings providing one, four or eight connections each. HIMs are connected to the CPB via ribbon cables.

The basic PAM 5000 system (PA03820000) contains the following:• Metal cabinet with CPB and power supply• POS HIM - One DSB 500 selectable wiring for RS-232/RS-422/CL 45 mA passive• Pump HIM - One DSB 492 CL 45 mA Active, 8 connections, up to 16 Fueling positions

(dual).

The following kits are available:• CL-interface kit M08037B001 (extend number of connections) which contains:

- One DSB 492 CL 45 mA Active, eight connections, up to 16 Fueling positions (dual). - One DSB (no.33) ribbon cable for connection to CPB Port. - One DSB (no.23) ribbon cable for interconnect DSB 492/DSB 492 if extend single

connections required on existing CPB port.• CRIND Basic kit M08037B002 which contains:

- One DSB 500 for POS. - One DSB 492 for CRIND device(s). - One DSMB (no.42) ribbon cable for supply power and interconnect DSB 500/DSB 492

modules.

HIMs such as DSB 492 and DSB 500 are constructed to reject echo feedback. Therefore, the CPB (for example, CPB509) software does not need to consider which type of signalling is used. As the PAM 5000 CRIND interface is based on the same modules, no echo feedback is present for the POS. The echo feedback is rejected for RS-232, RS-422 and CL.

Unpacking EquipmentUpon delivery, unpack each PAM 5000 system and inspect it for damage. Check each model and serial number with the packing list. Report all evident shipping damage to the carrier.

Note: Gilbarco’s warranty does not cover shipping damage.

After you have inspected all PAM 5000 equipment, store it indoors in its original shipping carton, until you install it. This protects the equipment from dirt and damage.

Note: Damage resulting from improper storage voids the Gilbarco warranty.


Introduction General Information

Always transport PAM 5000 equipment to a site in its original packaging to avoid damage to shock-sensitive components.

CAUTION

Returning EquipmentAll equipment or components returned under Gilbarco's warranty policy or for repair must be packaged properly to avoid shipping damage. Return equipment in its original shipping container. If the original materials are not available, use a durable reinforced corrugated box and suitable packing material (polyfoam chips, polyurethane foam chips, or polystyrene foam chips). Place printed circuit boards in antistatic shielding bags.

Do the following when you return the equipment:• Fill the bottom of the container with at least 2 inches of packing material.• Ensure that the device is firmly packed.• Include a description of the malfunction or damage, and return it with the shipping

information.• Prepare a Returned Goods Authorization form (MDE-2149 Warranty Return Materials

Authorization Form) to ship with the device.

Note: It is recommended that you fully insure the returned equipment. Gilbarco inspects all returned equipment for any damage caused during return shipment. The customer is responsible for all repair costs of the equipment that is damaged due to improper packing during return shipment.

Preliminary Site PreparationInspect the site and all delivered PAM 5000 equipment prior to equipment installation. Ensure that all necessary materials are present and the site meets all installation criteria, as specified in this manual and MDE-3620 Point of Sale Systems Site Preparation Manual.

Follow these guidelines and ensure that all requirements are met before installing the PAM 5000.

• The site’s electrical service must comply with all installation requirements for a complete fueling system. Installation must comply with National Electrical Code NFPA 70, the Automotive and Marine Service Station Code NFPA 30A, and local electrical codes.

• All receptacles providing power to PAM 5000 components must be properly installed, with a dedicated circuit; that is, isolated ground receptacle (Hubbell® #IG 5261 or equivalent). This type of receptacle is identified by the triangle embossed on the face of the outlet. The green grounding screw must be attached to the grounding conductor.

• The circuit powering the PAM 5000 must not power non-PAM 5000 devices. This circuit must not share a conduit with wiring for a device drawing high amperage (compressor, pump, Submerged Turbine Pump (STP), freezer, and so on), or a device which is a source of Radio Frequency Interference (RFI) such as a TV, microwave, intercom, two-way radio, and so on.

• Install all equipment (except devices installed at the island) in an enclosed, weatherproof structure. The room’s ambient temperature should not exceed 50 °C/122 °F. This maximum ambient temperature is allowed only if the equipment is allowed free air flow.

• Do not install equipment in areas exposed to direct sunlight. You must provide shade and protect the equipment from direct sunlight exposure.


Requirements Introduction

RequirementsThe environmental conditions required for the installation are tabulated below.

Parameter ValueTemperature Range, Operation 0 to +50 °C / 32 to +122 °F

Temperature Range, Storage -20 to +80 °C / -4 to +176 °F

Air Humidity, Maximum 90%, Non-condensing

It is recommended that the line cord grounding conductor be connected to the same grounding as the POS system and the connected pump electronics.

Notes: 1) The AC power is turned off by removing the AC cable plug from the inlet.

2) The AC cable must be installed as per local regulations.

3) Only Gilbarco supplied HIMs should be installed in the PAM 5000 cabinet.

Technical DataParameter ValueDimensions (H X W X D) 23.6” X 7.9” X 4.9”

Weight approx. 8 kg/18 pounds

Supply Voltage, Nominal 120 VAC

Max. power consumption 43 W

Fuse, 5 x 20 mm/0.2” x 0.8” Slow Blow T1A

Degree of protection IP 30

Wire inlets 2 pcs. 1”

2 pcs. 3/4”

1 pc. 1/2”

Cable LengthDSB 500 Interface RS-232 50' (15 meters)

DSB 492 Interface CL 45 mA AWG14 2600' (792 meters) AWG18 1300' (396 meters)


Introduction POS Equipment

POS EquipmentPOS equipment must:

• be on the same AC phase as the controller and have a dedicated circuit and isolated ground receptacle.

• be UL®-listed.• have an Electronics Industries Association (EIA) standard RS-232C communication

interface.• not be installed over a hazardous location.

System Regulatory ApprovalsSystem level approvals or certifications for Weights and Measures, FCC or other applicable agencies, are the responsibility of the POS integrator.


Important Safety Information

2 – Important Safety Information
This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or pressure release could occur and cause death or serious injury, if these safe service procedures are not followed.
Preliminary PrecautionsYou are working in a potentially dangerous environment of flammable fuels, vapors, and high voltage or pressures. Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment.

Emergency Total Electrical Shut-OffThe first and most important information you must know is how to stop all fuel flow to the pump/dispenser and island. Locate the switch or circuit breakers that shut off all power to all fueling equipment, dispensing devices, and Submerged Turbine Pumps (STPs).

The EMERGENCY STOP, ALL STOP, and PUMP STOP buttons at the cashier’s station WILL NOT shut off electrical power to the pump/dispenser. This means that even if you activate these stops, fuel may continue to flow uncontrolled.

You must use the TOTAL ELECTRICAL SHUT-OFF in the case of an emergency and not the console’s ALL STOP and PUMP STOP or similar keys.

! WARNING!

Total Electrical Shut-Off Before AccessAny procedure that requires access to electrical components or the electronics of the dispenser requires total electrical shut off of that unit. Understand the function and location of this switch or circuit breaker before inspecting, installing, maintaining, or servicing Gilbarco equipment.

Evacuating, Barricading and Shutting OffAny procedure that requires access to the pump/dispenser or STPs requires the following actions:

• An evacuation of all unauthorized persons and vehicles from the work area

• Use of safety tape, cones or barricades at the affected unit (s)

• A total electrical shut-off of the affected unit (s)

Read the ManualRead, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand a procedure, call a Gilbarco Authorized Service Contractor or call the Gilbarco Support Center at 1-800-800-7498. It is imperative to your safety and the safety of others to understand the procedures before beginning work.

Follow the RegulationsApplicable information is available in National Fire Protection Association (NFPA) 30A; Code for Motor Fuel Dispensing Facilities and Repair Garages, NFPA 70; National Electrical Code (NEC), Occupational Safety and Hazard Association (OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment.

Replacement PartsUse only genuine Gilbarco replacement parts and retrofit kits on your pump/dispenser. Using parts other than genuine Gilbarco replacement parts could create a safety hazard and violate local regulations.

Safety Symbols and Warning WordsThis section provides important information about warning symbols and boxes.Alert Symbol

This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death.Signal WordsThese signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions below must be followed to prevent death, injury or damage to the equipment:

DANGER: Alerts you to a hazard or unsafe practice which will result in death or serious injury.WARNING: Alerts you to a hazard or unsafe practice that could result in death or serious injury. CAUTION with Alert symbol: Designates a hazard or unsafe practice which may result in minor injury.CAUTION without Alert symbol: Designates a hazard or unsafe practice which may result in property or equipment damage

Working With Fuels and Electrical Energy

Prevent Explosions and FiresFuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. Even filling customer tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island.

!

!

!



No Open Fire

Open flames from matches, lighters, welding torches or other sources can ignite fuels and their vapors.No Sparks - No Smoking

Sparks from starting vehicles, starting or using power tools, burning cigarettes, cigars or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic charge on your body, can cause a spark sufficient to ignite fuel vapors. Every time you get out of a vehicle, touch the metal of your vehicle, to discharge any electrostatic charge before you approach the dispenser island.

Working AloneIt is highly recommended that someone who is capable of rendering first aid be present during servicing. Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, if you work with or around high voltages. This information is available from the American Red Cross. Always advise the station personnel about where you will be working, and caution them not to activate power while you are working on the equipment. Use the OSHA Lockout/ Tagout procedures. If you are not familiar with this requirement, refer to this information in the service manual and OSHA documentation.

Working With Electricity SafelyEnsure that you use safe and established practices in working with electrical devices. Poorly wired devices may cause a fire, explosion or electrical shock. Ensure that grounding connections are properly made. Take care that sealing devices and compounds are in place. Ensure that you do not pinch wires when replacing covers. Follow OSHA Lockout/Tagout requirements. Station employees and service contractors need to understand and comply with this program completely to ensure safety while the equipment is down.

Hazardous MaterialsSome materials present inside electronic enclosures may present a health hazard if not handled correctly. Ensure that you clean hands after handling equipment. Do not place any equipment in the mouth.

The pump/dispenser contains a chemical known to the State of California to cause cancer.

WARNING!

The pump/dispenser contains a chemical known to the State of California to cause birth defects or other reproductive harm.

WARNING!

In an Emergency

Inform Emergency PersonnelCompile the following information and inform emergency personnel:

• Location of accident (for example, address, front/back of building, and so on)

• Nature of accident (for example, possible heart attack, run over by car, burns, and so on)

• Age of victim (for example, baby, teenager, middle-age, elderly)

• Whether or not victim has received first aid (for example, stopped bleeding by pressure, and so on)

• Whether or not a victim has vomited (for example, if swallowed or inhaled something, and so on)

Gasoline ingested may cause unconsciousness and burns to internal organs.Do not induce vomiting.Keep airway open. Oxygen may be needed at scene.Seek medical advice immediately.

WARNING!

Gasoline inhaled may cause unconsciousness and burns to lips, mouth and lungs.Keep airway open.Seek medical advice immediately.

WARNING!

Gasoline spilled in eyes may cause burns to eye tissue.Irrigate eyes with water for approximately 15 minutes.Seek medical advice immediately.

!

WARNING!

Gasoline spilled on skin may cause burns.Wash area thoroughly with clear water.Seek medical advice immediately.

WARNING!

IMPORTANT: Oxygen may be needed at scene if gasoline has been ingested or inhaled. Seek medical advice immediately.

Lockout/TagoutLockout/Tagout covers servicing and maintenance of machines and equipment in which the unexpected energization or start-up of the machine(s) or equipment or release of stored energy could cause injury to employees or personnel. Lockout/Tagout applies to all mechanical, hydraulic, chemical or other energy, but does not cover electrical hazards. Subpart S of 29 CFR Part 1910 - Electrical Hazards, 29 CFR Part 1910.333 contains specific Lockout/Tagout provision for electrical hazards.



Hazards and Actions

WARNING

Spilled fuels, accidents involving pumps/dispensers, or uncontrolled fuel flow create a serious hazard.Fire or explosion may result, causing serious injury or death.Follow established emergency procedures.

!

The following actions are recommended regarding these hazards:

Collision of a Vehicle with Unit Fire at Island Fuel Spill

• Do not go near a fuel spill or allow anyone else in the area.• Use station EMERGENCY CUTOFF immediately. Turn off all system circuit breakers to the

island(s).• Do not use console E-STOP, ALL STOP and PUMP STOP to shut off power. These keys do not

remove AC power and do not always stop product flow.• Take precautions to avoid igniting fuel. Do not allow starting of vehicles in the area. Do not allow

open flames, smoking or power tools in the area.• Do not expose yourself to hazardous conditions such as fire, spilled fuel or exposed wiring.• Call emergency numbers.


PAM 5000 Installation Instructions Installation

3 – Installation

PAM 5000 Installation InstructionsTo install the PAM 5000 system, proceed as follows:

1 Make room for the box and wiring, on the right side of the cabinet.

2 Orient the cabinet correctly, by installing it in an upright position (preferred position), as shown in Figure 3-1. Else, the display will not be readable.

Figure 3-1: Installation Dimensions

7.9”8.7”

9.1”

6.7”

2.7”

2.8”

ø0.24”

18.3

”23

.6”


Installation PAM 5000 Installation Instructions

3 Ensure that the mounting surface is strong enough to support the cabinet's weight (maximum of 25 pounds including cables). Locate and mark the mounting points.

4 If the fastening device requires inserts in the mounting surface, drill the appropriate holes and install the inserts.Note: Up to 7/32 inch screws or bolts may be used.

5 Fasten the cabinet to the wall using fasteners suitable for the wall’s material. Ensure that you leave enough space for unplugging the AC plug and removing the fuse (see Figure 3-1 on page 13).

6 Open the cabinet by turning the two lock screws counterclockwise.

Figure 3-2: Open PAM 5000 Cabinet with Modules Installed

AC Transformer

Central Processor Board

Ethernet Port (For Diagnostic, Service, and Software Download)

1.4” DIN Rail

Wire Relief Bar

AC Filter

Pump Interface Modules

POS Interface Module


PAM 5000 Installation Instructions Installation

7 Turn on the power by connecting the AC cable to the inlet socket. The yellow 3 V and the 5 V Light Emitting Diodes (LEDs) turn on, indicating power-on. After approximately 10 seconds, the red APPL LED will start flashing. Turn off the power by unplugging the main AC cord.

8 Remove the seals from the wire inlet holes used in the installation. Install the conduits and conduit connectors (not included) in these holes.

9 Route the wires from the forecourt equipment through the conduits to the relevant HIMs. Use cable ties to fasten the wires to the Wire Relief Bar.

10 Connect the wires to the HIM connectors. Refer to “Installation Drawing - HIMs” on page 19 for making the connections.

Figure 3-3: Wires Tied to the Wire Relief Bar

11 If a network is available for PAM 5000 web services, connect the Ethernet RJ-45 CAT 5 STP cable to the connector located in the top right of the box. Set the required TCP/IP address (refer to MDE 4677 PAM 5000 Service Manual).

12 Turn on the power and ensure that the LEDs function as described in step 7.

13 Check HIM LED's function:• Pump (or CRIND) DSB 492 CL 45mA active,

Yellow = VDC power to the module, Green = TX out to all, Red= RX from device• POS, DSB 500 RS232/RS422/CL 45mA passive, selectable, Yellow = VDC power to the

module, Green = TX out to device, Red= RX from device.

For more information regarding diagnostic functions, refer to MDE 4677 PAM 5000 Service Manual.

14 Close the box by turning the lock screws clockwise.


Installation PAM 5000 Installation Instructions

Additional PrecautionsEach connected fuel dispenser must be marked with information about where to turn off AC power and interface power. The marking must include how to unplug the relevant connector from the PAM 5000 system, and where the PAM 5000 system is located.

In case of maintenance or repair, a single fuel dispenser can be isolated from the PAM 5000 system by unplugging the relevant connector from the HIM.

If local regulations require the fuel dispensers to be completely de-energized when the emergency stop is activated, the AC to the PAM 5000 system must be powered from a source that turns off when the emergency stop is activated.


Changing a Blown Fuse Replacing the Fuse

4 – Replacing the Fuse

Changing a Blown FuseThe fuse is located in the AC inlet socket. To change a defective fuse, proceed as follows:

1 Shut off power by unplugging the AC.

2 Open the Fuse Drawer with a small flat screwdriver (max 2.5 mm) by inserting the tip into the small hole next to the Fuse Drawer, as shown in Figure 4-1.

Figure 4-1: Opening the Fuse Drawer

3 Press the handle of the screwdriver carefully towards the box, so that the Fuse Drawer is pushed in the direction of the arrow and out.

4 Repeat steps 2 and 3 for the other side of the Fuse Drawer.

5 Remove the defective fuse from the Fuse Drawer and replace the fuse.

Notes:1) The Fuse Drawer is divided into two sections, to make room for a spare fuse. Use the spare fuse, if available. Ensure that it is a type T1A fuse of dimensions 5 x 20 mm.

2) Ensure that you detect the reason for the blown fuse and eliminate the problem.

6 Close the Fuse Drawer.

7 Restore power. The system should run normally.


Replacing the Fuse Changing a Blown Fuse



Installation Drawing - HIMs

5 – Installation Drawing - HIMs

Figure 5-1: DSB 500 HIM for POS Connection


Installation Drawing - HIMs

Figure 5-2: DSB 492 HIM for Pump (or CRIND) Connections

Notes:1. Shielded cable with the shield properly connected at both ends is recommended.2. The DSB 492 module must only be installed in a DOMS Forecout Controller Cabinet.3. Colors refer to the recommended DOMS cable: 2 X 2 X 0.5 mm2, stock number 119042.


PAM 5000 Configuration

6 – PAM 5000 Configuration

The PAM 5000 Basic system contains the following HIMs for connection to devices:• One DSB 500 (POS)• One DSB 492 (1-16 Fueling Positions - Dual)

Extend the numbers of current loop connections by adding the required number of DSB 492 (CL 45 mA) HIMs, available as a CL-Interface kit.

Optionally, extend PAM 5000 with a CRIND kit that is used as an interface between the POS and payment terminals.

Read more about kits in “HIMs” on page 5.

The different PAM 5000 installation drawings illustrated are as follows:• PAM 5000 Dual Sided Pumps, Handle up to 36 Fueling Positions (Dual) on page 22• PAM 5000 Single Sided Pumps, Handle up to 36 Fueling Positions (Single) on page 23• PAM 5000 Dual Sided Pump/CRIND, Handles up to 32 Fueling Positions and Interfaces

between POS and CRIND Devices (up to 32 Dual-sided) on page 24



Figure 6-1: PAM 5000 Dual Sided Pumps, Handle up to 36 Fueling Positions (Dual)

Note:PORT 11: POSPORT 12: Pump 1-16 (Default Setting)PORT 13: Pump 17-32 (Default Setting)PORT 14: Pump 33-36 (Default Setting)



Figure 6-2: PAM 5000 Single Sided Pumps, Handle up to 36 Fueling Positions (Single)

Note:PORT 11: POSPORT 12: Pump 1-16 (Default Setting)PORT 13: Pump 17-32 (Default Setting)PORT 14: Pump 33-36 (Default Setting)



Figure 6-3: PAM 5000 Dual Sided Pump/CRIND, Handles up to 32 Fueling Positions and Interfaces between POS and CRIND Devices (up to 32 Dual-sided)

Note:PORT 11: POSPORT 12: Pump 1-16 (Default Setting)PORT 13: Pump 17-32 (Default Setting)PORT 21: CRIND Devices 1-32 (Power to

the CRIND Modules)


Index

Index

AAlert symbol 9

BBarricading 9

CCaution warnings 9

DDanger warnings 9

EElectrical

Shut-off 9Emergency

Electrical shut-off 9In Case Of 11Personnel (contacting) 10

Evacuation 9Explosions

Preventing 9

FFires

Preventing 9Fuse 17Fuse Drawer 17

HHardware Interface Modules 7

PPAM 5000 1Personnel

Emergency (informing) 10Point of Sale (POS) 3

RRequirements 7

SS

TT

WWW

MDE-4676 PAM™ 5000 Installation Manual

afety Information 9Alert symbol 9Barricading 9Emergency electrical shut-off 9Emergency personnel 10Evacuation 9NFPA regulations 9Open flames 10Preventing explosions and fires 9Regulations 9Replacement parts 9Safety symbols 9Shut-off 9Signal words 9Smoking 10Sparks 10Warning words 9Working alone 10

Safety symbols 9Shut-off 9

Emergency electrical 9Signal words

Safety 9

echnical Data 7

arning words 9arnings 9

· February 2008 Index-1

Index

Hubbell® is a registered trademark of Hubbell Incorporated. PAM™ 5000 is a trademark of Gilbarco Inc. UL® is a registered trademark of Underwriters Laboratories Inc.

© 2008 Gilbarco Inc. 7300 West Friendly Avenue · Post Office Box 22087Greensboro, North Carolina 27420 Phone (336) 547-5000 · http://www.gilbarco.com · Printed in the U.S.A. MDE-4676 PAM™ 5000 Installation Manual · February 2008

http://www.gilbarco.com

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